Petroleum Refineries 16 Number of Jobs Risk Assessment Sheet (part-01)

		ACTIVITY : ASSEMBLY OF SPARE CUTTER HEAD
		FREQUENCY :	As per requirement.
		PURPOSE OF JOB :	To keep ready assembled spare cutter head for extruders to save time of assmbling during replacement.
		SUB ACTIVITIES :	1. Shifting cutter head on working table.
			2. Opening of cutter blade bolts and removal of cutter blades .
			3. Cleaning and polishing of holder surface.
			4. Fixing new cutter blades and tightening cutter blade bolts.
			5. Shifting the cutter head on surface plate for alignment.
			6. Carry out alignment of cutter blades.
			7. Shifting the ready cutter head to designated place/box.
SUB ACTI. SR. NO.	HAZARDS THAT MAY BE ENCOUNTERED	SOURCE / CAUSE OF HAZARD	CONTROL MEASURES PROVIDED	CONTROL MEASURES TO BE PROVIDED	ADDITIONAL SAFETY PRECAUTION / INSTRUCTIONS	RISK ANALYSIS
1 to 7	Physical injury	Slippage of allen key during opening / tightening of cutter blade bolts.	Use of basic PPE's.	Discard damaged allen bolt if any.	Use of correct size of allen key for opening and tightening bolts.	Risk is Controlled.
		Injury due to sharp edges of cutter blades during shifting and assembly.	Use of cut resistant leather hand gloves.	Use special fixing plate during shifting cutter head.	Use of exact tools and tackles. Tool box talk.	Risk is Controlled.
	Others	In case of any emergency/injury	Wind direction,  Escape route, Assembly point,    Fire extinguisher     Manual call point,      Loudophone   Safety shower,Work carried out below or above	All the safety measures provided in the plant nearest to the job must be spotted before job starts.	Supervisor shall explain all these during the tool box talk before start of each job.	Risk is controlled.

		ACTIVITY : EOT operation
		FREQUENCY :	During major overhauling or when required.
		PURPOSE OF JOB :	Lifting and shifting of heavy objects.
		SUB ACTIVITIES :	1. Operation of EOT crane with / without load.
SUB ACTI. SR. NO.	HAZARDS THAT MAY BE ENCOUNTERED	SOURCE / CAUSE OF HAZARD	CONTROL MEASURES PROVIDED	CONTROL MEASURES TO BE PROVIDED	ADDITIONAL SAFETY PRECAUTION / INSTRUCTIONS	RISK ANALYSIS
1	Injury / damage to the machines / equipments / spare parts.	Failure of hoist brake.	1. Periodical servicing of break mechanism. 2. Load testing of the hoist with rated load.` 3. Use basic PPE's	1. Ensure the weight of the object being lifted is within the capacity of the EOT crane. 2. Verify and ensure that the servicing of the EOT crane has been done within the validity period. 3. Ensure that the speed of hoist movement is maintained within safe limits.	1. Check and ensure functioning of the hoist brake before taking up critical jobs. 2. Use exact size and certified lifting tools / tackles for the job.	Risk is controlled.
		Failures / breakage of wire rope.	1. Periodical servicing & load testing of EOT crane before major overhauling jobs. 2. Use basic PPE's	1. Ensure the weight of the object being lifted is within the capacity of the EOT crane. 2. Verify and ensure that the servicing of the EOT crane has been done within the validity period. 3. Maintain safe working distance of all persons from the lifted load.	1. Ensure servicing & load testing of EOT crane before taking up critical jobs like major overhauls of equipments. 2. Inspect wire rope for good condition before the job.	Risk is controlled.
		Movement of carriage with load.	1. Ensure that lifting scheme / slinging arrangement is applied. 2. Ensure there are no movement of people in the area of operation. 3. Barricade the movement path if required. Use basic PPE's	1. Use hooter or buzzer to warn persons where required. 2. Ensure that the speed of crane movement is maintained within safe limits. 3. Ensure coordination between the crane operator and other persons working on the job (especially for remote operated and cabin operated cranes).	While operating the crane maintain safe distance from the load.	Risk is controlled.
		Fall of material/load	Use basic PPE's	Safety latch to be provided in the lifting hook. Use of certified tools & tackles.& ensure that pslings are clamped & positioned inside lifting hook.	Ensure that no person stands directly below the hookwith load in it.	Risk is controlled.
	Others	In case of any emergency/injury	Wind direction,  Escape route, Assembly point,    Fire extinguisher     Manual call point,      Loudophone   Safety shower,Work carried out below or above	All the safety measures provided in the plant nearest to the job must be spotted before job starts.	Supervisor shall explain all these during the tool box talk before start of each job.	Risk is controlled.
	NOTE: This risk assessment is valid if surrounding conditions are normal. It will change according to the change in surrounding conditions.

		ACTIVITY : EOT Load testing using metal block.
		FREQUENCY :	Yearly
		PURPOSE OF JOB :	Statutory requirement
		SUB ACTIVITIES :	1. Shifting of required load to the job site.
			2. Inspection and servicing of the EOT crane.
			3. Load testing.
			4. Shifting of load from job site.
SUB ACTI. SR. NO.	HAZARDS THAT MAY BE ENCOUNTERED	SOURCE / CAUSE OF HAZARD	CONTROL MEASURES PROVIDED	CONTROL MEASURES TO BE PROVIDED	ADDITIONAL SAFETY PRECAUTION / INSTRUCTIONS	RISK ANALYSIS
1to 4	Injury.	Falling of heavy object.	Use basic PPE's.	Keep safe working distance from hanging load & be cautious about hook, sling, 'D'-shackle failure.	None.	Risk is controlled.
		Failure of lifting tools & tackles	Use tested tools & tackles	Keep safe working distance from hanging load & be cautious about hook, sling, 'D'-shackle failure.		Risk is controlled.
		1. Handling heavy equipments. 2. Using improper tools.	1. Use Tested lifting tools & tackles 2. Use basic PPE's.	.Lifting hooks to be provided with safety latch.	1. Ensure safe distance from the equipment while lifting by chain pulley block & crane. 2. Tool box talk to be given to all persons involved in the job. 3. Load to be lifted equally by all the people. 4. Jacks & pullers must be in good condition.	Risk is Controlled.
4	Fall from height.	Breaking of chain, sling, hook, 'D'-shackle etc.	Use basic PPE's.	Keep safe working distance from hanging load & be cautious about hook, sling, 'D'-shackle failure	Barricade the working area.	Risk is controlled.
1 & 4	physical injury	Person may slip while working on the job.	use basic PPE's & full body harness with Double lanyard.	Certified scaffolding to be provided	Do not take support of the spanner while loosening or tightening the bolts.	Risk is controlled.
	Others	In case of any emergency/injury	Wind direction,  Escape route, Assembly point,    Fire extinguisher     Manual call point,      Loudophone   Safety shower,Work carried out below or above	All the safety measures provided in the plant nearest to the job must be spotted before job starts.	Supervisor shall explain all these during the tool box talk before start of each job.	Risk is controlled.
	NOTE: This risk assessment is valid if surrounding conditions are normal. It will change according to the change in surrounding conditions.

		ACTIVITY : DIE PLATE REPLACEMENT
		FREQUENCY :	As per requirement.
		PURPOSE OF JOB :	To replace die plate for cleaning / reconditioning / replacement as per matrix.
		SUB ACTIVITIES :	1. Ensure electrical and process (steam and DM water) isolation.
			2. Draining hot water of PCW chamber.
			3. Removal of cutter head.
			4. Opening of auxiliary lines, PCW chamber and shifting of carriage.
			5. Replacement of old die plate with re-conditioned / new one.
			6. Boxing up auxiliary lines.
			7. Installation of new cutter head and shifting old cutter head to mechanical workshop.
			8. Hot alignment, zero setting and grinding of cutter head.
SUB ACTI. SR. NO.	HAZARDS THAT MAY BE ENCOUNTERED	SOURCE / CAUSE OF HAZARD	CONTROL MEASURES PROVIDED	CONTROL MEASURES TO BE PROVIDED	ADDITIONAL SAFETY PRECAUTION / INSTRUCTIONS	RISK ANALYSIS
1 to 8	Physical injury	Slippage due to improper working place.	1) Use of basic PPE's. 2) Thorough cleaning of work place.	Ensure good house keeping.	Tool box talk.	Risk is Controlled.
		Slippage of tools during opening / boxing up flanges and allen bolts of die plate.	Use of correct tools and tackles. Use the tools from right position.	1) Ensure proper cleaning of allen bolt socket before applying allen key. Periodical checking of tools and tackles. 2) Ensure use of correct tools.	Tool box talk.	Risk is Controlled.
		Slippage during lifting and mounting of die plate.	Use of correct tools and tackles.	Use of tested chain pulley block, D-shackles and wire slings.	Tool box talk.	Risk is Controlled.
		Due to sharp edges of cutter blades during mounting and shifting cutter head.	1) Use of cut resistant lather hand gloves. 2) Electrical lock out on cutter motor.	1) Hold cutter shaft at motor coupling during opening/ tightening of cutter head allen bolt. 2) Cross check electrical isolation of cutter motor by pressing local switch.	1) Use of proper tools and tackles. 2) Tool box talk 3) Ensure electrical lock out tag on local switch.	Risk is Controlled.
1,2,6, 8	Hot burn	1) Hot die plate and PCW chamber. 2) Hot PCW water. 3) Hot Thermofluid, LP steam.	1) Proper draining of PCW chamber 2) Ensure electrical lock out on PCW pump.	1) Running water hose to be provided nearby 2) Cross check electrical isolation of PCW pump motor by pressing local switch.	1) Use of full sleeve cut resistance leather gloves. 2) Tool box talk. 3) Ensure electrical lock out tag on local switch.	Risk is Controlled.
	Others	In case of any emergency/injury	Wind direction,  Escape route, Assembly point,    Fire extinguisher     Manual call point,      Loudophone   Safety shower,Work carried out below or above	All the safety measures provided in the plant nearest to the job must be spotted before job starts.	Supervisor shall explain all these during the tool box talk before start of each job.	Risk is controlled.

		ACTIVITY : BLOWER AND COMPRESSOR BELT REPLACEMENT
		FREQUENCY :	As per requirement.
		PURPOSE OF JOB :	To replace worn out / damaged / schedule replacement of belts.
		SUB ACTIVITIES :	1. Ensure electrial isolation.
			2. Ensure process isolation.
			3. Removal of belt guard.
			4. Loosening of motor foundation bolts and taking the motor towards blower/compressor.
			5. Removal of fly-wheel plummer block.
			6. Replacement of belts and boxing up the plummer block.
			7. Alignment of pulleys and tensioning of belts.
			8. Tightening of motor foundation bolts.
			9. Boxing up belt guard.
SUB ACTI. SR. NO.	HAZARDS THAT MAY BE ENCOUNTERED	SOURCE / CAUSE OF HAZARD	CONTROL MEASURES PROVIDED	CONTROL MEASURES TO BE PROVIDED	ADDITIONAL SAFETY PRECAUTION / INSTRUCTIONS	RISK ANALYSIS
1 to 9	Physical injury.	During removal and boxing up of belt guard .	a) Use of basic PPE's.	Periodic calibration of lifting tools and tackles	1) Use of tested chain pulley block, wire rope slings and D-shackles . 2) Tool box talk for CP block usage.	Risk is Controlled.
		During opening and tightening of foundation bolts / jack bolts.		Use of proper platform/ scaffolding where ever required	Use of exact size of tools and tackles.	Risk is Controlled.
		Injury to fingers during replacement of belts and alignment of pulleys.		Sufficient margin to be made between motor and compressor/blower for ease in belt replacement.	1) Proper and effective co-ordination among working crew. 2) Tool box talk regarding belt replacement.	Risk is Controlled.
		Sudden / reverse rotation of rotor.	1) Ensure electrical isolation. 2) Ensure Process isolation.	1) Cross check electrical isolation by pushing local button. 2) Operator to conform positive isolation.	1) Check electrical isolation tag on local switch before starting the job 2) Ensure "DO NOT OPERATE" tag on isolation valves.	Risk is Controlled.
	Others	In case of any emergency/injury	Wind direction,  Escape route, Assembly point,    Fire extinguisher     Manual call point,      Loudophone   Safety shower,Work carried out below or above	All the safety measures provided in the plant nearest to the job must be spotted before job starts.	Supervisor shall explain all these during the tool box talk before start of each job.	Risk is controlled.

		ACTIVITY : Attending Valve Gland Leakages of Fuel Oil(HSD/LSHSH/MIX OIL) & Fuel Gas(Lean Gas).
		FREQUENCY :	As & when required.
		PURPOSE OF JOB :	To arrest the valve gland leakages of Steam& water .
		SUB ACTIVITIES :	1. Erection & Dismantling of Scaffolding
			2. Opening of stuffing box.
			3. Addition/Replacement of Gland packing
			4. Gland Tightening.
SUB ACTIVITY. SR. NO.	HAZARDS THAT MAY BE ENCOUNTERED	SOURCE / CAUSE OF HAZARD	CONTROL MEASURES PROVIDED	CONTROL MEASURES TO BE PROVIDED	ADDITIONAL SAFETY PRECAUTION / INSTRUCTIONS	RISK ANALYSIS
1,2,3& 4	Injury	1. Fall from Height 2. Sharp edge, slipping of tool.	Use of basic PPE's .	1. Certified Scaffolding for working. 2.standard tools to be used.	1.Tested full body harness with Double lanyard. is to be used while going up or climbing down during 2.Defective fasteners / tools to be replaced. 3. Ensure that the hands & tools are free from Oils & greases.	Risk is Controlled. Ref NC/E&M(MEC)RAF 35
2	Splashing of Fluids.	Etrpped Fluids inside the pipeline.	1. Draining & isolation of the pipe line to be ensured. 2.check for Display of "Do Not Operate" Tag	Asbestos / PVC / cotton gloves / suit to be used,	1. Loosen the gland bolts slowly to drain out any trapped fluid. 2. Do not use steel 3. Use the Face Shield while crack opening	Risk is Controlled.
	Hot burns.	Hot area or hot metal surfaces.	Cover the nearby hot surfaces with asbestos blanket.	Additional Use of Basic PPE's as mentioned in WP	1. Awareness of the surrounding area at job site. 2. Tool box talk to be given.	Risk is Controlled.
	Fire	1. Auto Ignition of leaky Hot Fluids. 2. Spark generated with tools	1. Complete Draining & isolation of the pipe line to be ensured. 2. Do not start the job till all the leaky fluids are neutralized /Area is Hydrocarbon free. 3. Use non Sparking Tools & brass hammer.	1. Additional Use of Basic PPE's as mentioned in WP 2. Keep DCP near the work spot	1. To loosen the bolts use 'F' type valve key or pipe for extra leverage. 2. Cover the near by Instruments & Cables with Asbestos Blankets 3. Check, ensure and mark proper escape route	Risk is Controlled.
	Others	In case of any emergency/injury	Wind direction,  Escape route, Assembly point,    Fire extinguisher     Manual call point,      Loudophone   Safety shower,Work carried out below or above	All the safety measures provided in the plant nearest to the job must be spotted before job starts.	Supervisor shall explain all these during the tool box talk before start of each job.	Risk is controlled.

		ACTIVITY : Attending Valve Gland Leakages steam & water by replacement of Gland Packing.
		FREQUENCY :	As & when required.
		PURPOSE OF JOB :	To arrest the valve gland leakages of Steam& water .
		SUB ACTIVITIES :	1. Erection & Dismantling of Scaffolding
			2. Opening of stuffing box.
			3. Addition/Replacement of Gland packing
			4. Gland tightening.
SUB ACTI. SR. NO.	HAZARDS THAT MAY BE ENCOUNTERED	SOURCE / CAUSE OF HAZARD	CONTROL MEASURES PROVIDED	CONTROL MEASURES TO BE PROVIDED	ADDITIONAL SAFETY PRECAUTION / INSTRUCTIONS	RISK ANALYSIS
1,2,3 &4	Injury	1. Sharp edges, slipping of tool. 2. Fall from Height	Use of basic PPE's.	1. Correct size tool to be used. 2. Standard Scaffolding to be used	1. Defective bolt / tools to be replaced. 2. Tested Double Hooked full body harness with Double lanyard. is to be used while going up or climbing down	Risk is Controlled.
1	Splashing of Fluid .	Liquid inside the pipeline.	Draining & isolation of the pipe line to be ensured.	Asbestos / PVC gloves / suit to be used,	1. Loosen the gland bolts slowly to drain out any trapped fluid. 2. Face Shield is to be used while crack opening	Risk is Controlled.
	Hot burns.	1. Hot area or hot metal surfaces. 2. Splashing of liquid.	Cover the nearby hot surfaces with asbestos blanket.	Asbestos Gloves to be used.	1. Awareness of the surrounding area at job site. 2. Tool box talk.	Risk is Controlled.
	Others	In case of any emergency/injury	Wind direction,  Escape route, Assembly point,    Fire extinguisher     Manual call point,      Loudophone   Safety shower,Work carried out below or above	All the safety measures provided in the plant nearest to the job must be spotted before job starts.	Supervisor shall explain all these during the tool box talk before start of each job.	Risk is controlled.

		ACTIVITY : Attending Valve Gland Leakages of Fuel Oil(HSD/LSHSH/MIX OIL) & Fuel Gas(Lean Gas).
		FREQUENCY :	As & when required.
		PURPOSE OF JOB :	To arrest the valve gland leakages of Steam& water .
		SUB ACTIVITIES :	1. Erection & Dismantling of Scaffolding
			2. Opening of stuffing box.
			3. Addition/Replacement of Gland packing
			4. Gland Tightening.
SUB ACTIVITY. SR. NO.	HAZARDS THAT MAY BE ENCOUNTERED	SOURCE / CAUSE OF HAZARD	CONTROL MEASURES PROVIDED	CONTROL MEASURES TO BE PROVIDED	ADDITIONAL SAFETY PRECAUTION / INSTRUCTIONS	RISK ANALYSIS
1,2,3& 4	Injury	1. Fall from Height 2. Sharp edge, slipping of tool.	Use of basic PPE's .	1. Certified Scaffolding for working. 2.standard tools to be used.	1.Tested full body harness with Double lanyard. is to be used while going up or climbing down during 2.Defective fasteners / tools to be replaced. 3. Ensure that the hands & tools are free from Oils & greases.	Risk is Controlled. Ref NC/E&M(MEC)RAF 35
2	Splashing of Fluids.	Etrpped Fluids inside the pipeline.	1. Draining & isolation of the pipe line to be ensured. 2.check for Display of "Do Not Operate" Tag	Asbestos / PVC / cotton gloves / suit to be used,	1. Loosen the gland bolts slowly to drain out any trapped fluid. 2. Do not use steel 3. Use the Face Shield while crack opening	Risk is Controlled.
	Hot burns.	Hot area or hot metal surfaces.	Cover the nearby hot surfaces with asbestos blanket.	Additional Use of Basic PPE's as mentioned in WP	1. Awareness of the surrounding area at job site. 2. Tool box talk to be given.	Risk is Controlled.
	Fire	1. Auto Ignition of leaky Hot Fluids. 2. Spark generated with tools	1. Complete Draining & isolation of the pipe line to be ensured. 2. Do not start the job till all the leaky fluids are neutralized /Area is Hydrocarbon free. 3. Use non Sparking Tools & brass hammer.	1. Additional Use of Basic PPE's as mentioned in WP 2. Keep DCP near the work spot	1. To loosen the bolts use 'F' type valve key or pipe for extra leverage. 2. Cover the near by Instruments & Cables with Asbestos Blankets 3. Check, ensure and mark proper escape route	Risk is Controlled.
	Others	In case of any emergency/injury	Wind direction,  Escape route, Assembly point,    Fire extinguisher     Manual call point,      Loudophone   Safety shower,Work carried out below or above	All the safety measures provided in the plant nearest to the job must be spotted before job starts.	Supervisor shall explain all these during the tool box talk before start of each job.	Risk is controlled.

			ACTIVITY : Attending Steam Leaks Through Flange Joints.
			FREQUENCY :	As per requirement.
			PURPOSE OF JOB :	To arrest steam leakages through flange Joint.
			SUB ACTIVITIES :	1. Erection & Dismantling of Scaffolding
				2 Flange opening,
				3. Gasket replacement.
				4 Flange tightening.
	SUB ACTI. SR. NO.	HAZARDS THAT MAY BE ENCOUNTERED	SOURCE / CAUSE OF HAZARD	CONTROL MEASURES PROVIDED	CONTROL MEASURES TO BE PROVIDED	ADDITIONAL SAFETY PRECAUTION / INSTRUCTIONS	RISK ANALYSIS
	1,2,3&4	Injury	1. Sharp edge, slipping of tool. 2. Fall from Height	Use basic PPE's	Additional PPEs to be used as per work permit	1 Defective bolt / tool to be replaced. 2. Tested full body harness with Double lanyard. is to be used while going up or climbing down	Risk is Controlled.
	2	Hot Burns	1. Splashing of Hold up of condensate/Water/Steam inside the pipeline. 2. Hot area or hot metal surfaces.	1. Draining & isolation of the pipe line to be ensured. 2. Cover the nearby hot surfaces with asbestos blanket.	1. Asbestos gloves to be used. 2. Face shield is to be used for initial crack opening	1. Loosen the flange joint bolts (from opposite side of you) slowly to drain out any trapped liquid. 2. Proper attention to be paid to nearby objects.	Risk is Controlled.
		Others	In case of any emergency/injury	Wind direction,  Escape route, Assembly point,    Fire extinguisher     Manual call point,      Loudophone   Safety shower,Work carried out below or above	All the safety measures provided in the plant nearest to the job must be spotted before job starts.	Supervisor shall explain all these during the tool box talk before start of each job.	Risk is controlled.

		ACTIVITY : PREVENTIVE MAINTENANCE FOR CENTRIFUGAL PUMPS.
		FREQUENCY :	Three months / Six months / One year.
		PURPOSE OF JOB :	Increase reliability of equipment.
		SUB ACTIVITIES :	1. Electrical lockout.
			2. Decoupling the pump.
			3. Alignment checking and rectification.
			4. Lube oil checking / replacement.
			5. Rousing suction / discharge valve.
			6. Checking / Cleaning of suction strainer.
			7. Coupling of pump and motor.
			8. Checking cooler.
			9. Other checks as per SAP checklist / PM card.
			10. Lifting electric lockout.
SUB ACTI. SR. NO.	HAZARDS THAT MAY BE ENCOUNTERED	SOURCE / CAUSE OF HAZARD	CONTROL MEASURES PROVIDED	CONTROL MEASURES TO BE PROVIDED	ADDITIONAL SAFETY PRECAUTION / INSTRUCTIONS	RISK ANALYSIS
1,2,3,7,8	Physical injury.	Electrical motor/ Prime mover not stopped.	Ensure electrical lockout.	Confirm through operator by pushing the switch ON.	Tag "DO NOT OPERATE" to be provided at local and substation switch.	Risk is Controlled.
		Slippage of tools.	Use proper and standard tools from right position.	Check the tools periodically. .	Tool box talk is to be given.	Risk is Controlled.
		Falling of machine or cooler part.	Handle the Parts carefully. If required use proper lifting tool and rope.	Use of tested lifing tools.		Risk is Controlled.
		Injury due to unsafe adjacent equipments like leakage through nearby pipes,valves (or) moving parts of adjacent pump/machinery.	Use basic PPEs	Ensure safe working conditions surrounding the pump(Refer TBRA/GC/MEC/03)		Risk is Controlled.
		Fall of person due to Wet & slippery surface	Ensure working surface is free from oil ,water or any slippery material/algae formation	Confirm good house keeping periodically.		Risk is Controlled.
4,5,6,8	Chemical Exposure.	Pump not isolated / Isolation valve passing / Not Drained properly.	Start the job after consulting the area operator. Confirm zero pressure on PG. Confirm drain valve is Open & procees liquid is drained fully.	Put the Tag " DO NOT OPERATE" on Isolation valve. Confirm through proper isolation & draining		Risk is Controlled.
	Others	In case of any emergency/injury	Wind direction,  Escape route, Assembly point,    Fire extinguisher     Manual call point,      Loudophone   Safety shower,Work carried out below or above	All the safety measures provided in the plant nearest to the job must be spotted before job starts.	Supervisor shall explain all these during the tool box talk before start of each job.	Risk is controlled.
	NOTE: This risk assessment is valid if surrounding conditions are normal. It will change according to the change in surrounding conditions.

		ACTIVITY : Overhauling / PM job on Fan or blowers.
		FREQUENCY :	As per PM schedule / whenever required.
		PURPOSE OF JOB :	PM job, minor or major maintenance jobs of the Fan or Blower.
		SUB ACTIVITIES :	1. Blinding & Deblinding.
			2. Dismantling
			3. Cleaning/Polishing
			4. Alignment.
SUB ACTI. SR. NO.	HAZARDS THAT MAY BE ENCOUNTERED	SOURCE / CAUSE OF HAZARD	CONTROL MEASURES PROVIDED	CONTROL MEASURES TO BE PROVIDED	ADDITIONAL SAFETY PRECAUTION / INSTRUCTIONS	RISK ANALYSIS
1	Flashing of Fluid	Splashing of Hold up inside the system/pipeline.	1. Use of Basic PPEs 2. Draining & isolation of the pipe line to be ensured. 3. Isolation of suction & discharge valves required.	1) Ensure E.L.O. 2) "Do not operate" tag to be provided on isolation valves.	1. Display of E.L.O. tag in field. 2. Ensure that stop button on local switch should be in pressed condition.	Risk is controlled.
1 to 4	Injury	Fan rotation due to auto start of motor.	1) Electric isolation of main motor & isolation damper motor. 2) isolation of suction & discharge valves required.	1) E.L.O. to be taken. 2) "Do not operate" tag to be provided on isolation valves.	1. Display of E.L.O. tag in field. 2. Ensure that stop button on local switch should be in pressed condition.	Risk is controlled.
		Sharp edge, slipping of tool.	Use of Basic PPEs	Job specific tools to be used.	Defective bolt / tools to be replaced	Risk is Controlled.
		Lifting, shifting & placing heavy objects.	Use certified lifting tools with proper color coding.	None.	Proper selection of tools depending of the job undertaken.	Risk is controlled.
		1. Fall from height due 2.Slip while working on the job. 3.Insfficient Space on the Foundation.	1. Ensure no oily/greasy surfaces. 2. Certified scaffolding to be provided.	None.	1. Do not balance your weight on the spanner while loosening or tightening the bolts. 2. Care should be taken to keep balance while applying leverage.	Risk is Controlled.
3	Inhalations or ingestion by any route	Fine lapping Powder/Cleansing Solvents	Use Dust mask to mitigate the chances of ingestion by nasal/oral route	None.	1. Ensure that other agencies are not working close to the area being cleaned/worked upon. 2. If necessary, instruct them to comply with the control measures specified here.	Risk is Controlled
	Others	In case of any emergency/injury	Wind direction,  Escape route, Assembly point,    Fire extinguisher     Manual call point,      Loudophone   Safety shower,Work carried out below or above	All the safety measures provided in the plant nearest to the job must be spotted before job starts.	Supervisor shall explain all these during the tool box talk before start of each job.	Risk is controlled.

		ACTIVITY : ON LINE LEAK SEALING JOBS.
		FREQUENCY :	Intermittent.
		PURPOSE OF JOB :	To arrest the leak where isolation is not possible.
		SUB ACTIVITIES :	1. Pneumatic dling & threading.
			2. Pneumatic caulking.
			3. Clamping.
			4. Injection of fermaniting material.
SUB ACTI. SR. NO.	HAZARDS THAT MAY BE ENCOUNTERED	SOURCE / CAUSE OF HAZARD	CONTROL MEASURES PROVIDED	CONTROL MEASURES TO BE PROVIDED	ADDITIONAL SAFETY PRECAUTION / INSTRUCTIONS	RISK ANALYSIS
1	Fire, if leaking fluid contains hydrocarbon.	Spark during caulking / dling.	Measure Hydrocarbon content near the leak. Use running water spray over the leak.	Keep fire extinguisher ready.	Tool box talk is to be given. Protect nearby pipeline flanges/valves carrying hydrocarbons with wet blankets.	Risk is Controlled.
1,2,3	Burn injury.	Splash of leaking fluid.	Wear basic PPE's.	Use face shield, special suit and gloves as per work permit.	Use running water spray over the leaking area. Tool box talk is to be given.	Risk is Controlled.
1,2,3,4	Physical injury.	Tools & tackles	Use job specific tools and tackles from right position.	Use inspected tools and tackles only.	Tool box talk is to be given.	Risk is Controlled.
		Bursting of pressurised hose of air.	Use standard & tested hose. Do not twist the hose while using.	Periodical check up of hose and hydraulic equiptment used.		Risk is Controlled.
		Bursting of leaking line / fitting.	Do any operation on leaking line or fitting very slowly, gradually and carefully.	Healthiness of the line to be ensured before starting. During execution if leak is increasing, stop the operation.	Standby person to be continously available. Tool box talk to be given.	Risk is Controlled.
		Fall from height	If work is on height, scaffolding to be erected as per standards.	Inspection of scaffolding before use with ok tag diplayed & duly signed. Work to be carried maintaining proper body posture.	Escape route to be cleared	Risk is Controlled.
3	Damage of clamp.	Improper clamp.	Use standard material and thickness for clamp and its bolting.	Test certificate for MOC for the clamp and Bolting material as per line spec.	Nil	Risk is Controlled.
	Others	In case of any emergency/injury	Wind direction,  Escape route, Assembly point,    Fire extinguisher     Manual call point,      Loudophone   Safety shower,Work carried out below or above	All the safety measures provided in the plant nearest to the job must be spotted before job starts.	Supervisor shall explain all these during the tool box talk before start of each job.	Risk is controlled.
	NOTE: This risk assessment is valid if surrounding conditions are normal. It will change according to the change in surrounding conditions.

		ACTIVITY : MAN ENTRY IN COLUMN AND VESSEL (EQUIPTMENT)
		FREQUENCY :	Intermittent.
		PURPOSE OF JOB :	Internal inspection and / or rectification job.
		SUB ACTIVITIES :	1. Isolation of equipment.
			2. Making the equipment empty.
			3. Blinding of all connected lines as per blinding diagram & opening of manholes.
			4. Water / condensate wash and air purging.
			5. Checking of oxygen content, LELand temperature in equipment.
			6. Man entry for checking / rectification of job.
			7. De-blinding of all connected lines and boxing up manholes.
			8. Leak test.
SUB ACTI. SR. NO.	HAZARDS THAT MAY BE ENCOUNTERED	SOURCE / CAUSE OF HAZARD	CONTROL MEASURES PROVIDED	CONTROL MEASURES TO BE PROVIDED	ADDITIONAL SAFETY PRECAUTION / INSTRUCTIONS	RISK ANALYSIS
1,2,3,4,6,7,8	Physical injury.	1. Tools / tackles and wrong method of its application. 2. Fall from hieght. Due to darkness.	1. Use of exact size of tools and tackles from right position. 2. Use basic PPE's and full body harness with Double lanyard. 3. Provision of hand lamp.	1. Periodical checking & testing of tools / tackles. 2. Inspected rope ladder to be used while climbing down (e.g. inside sphere) 3. Torch to be carried.	Tool box talk is to be given.	Risk is Controlled.
1,6,8	Chemical exposure.	Residual chemicals. Passing of isolation valve.	1. Contact area operator. 2. Confirm zero pressure of PG. 3. Confirm the drain valve fully open.	1. Put 'Do not operate' tag on isolation valve. 2. Electrical lock out of the rotary machinery connected to the equiptment if any. 3. First loose the flange by standing away from the flange and opening opposite bolts.	1. Checking with hydrocarbon meter while opening the flange. 2. Tool box talk is to be given.	Risk is Controlled.
		Improper blinding.	Correct blinding as per blinding diagram is to be ensured.	Blinding should be as per diagram & blind register is to be maintained.	1. Checking with hydrocarbon meter. 2. Tool box talk is to be given.	Risk is Controlled.
5,6	Breathing problem.	1. Improper purging with air. 2. Lack of continuous air flow inside the equiptment.	1.Ventilation is to be provided.	1. Ensure adequate O2 concentration. Put 'Do not operate' tag from where air connection is given to the equipment. 2. To maintain circulation of air top vent or manhole should be kept open. 3. Basic PPE's and safety belt should be used.	1. Continuous air purging should be maintained. 2. Presence of standby person outside the equiptment who will control the entry. 3. Tool box talk is to be given.	Risk is Controlled.
3,6	Fire	Residual hydrocarbons.	Checking of Hydrocarbon prior to entery/rectification / inspection in to the equiptment.	Make fire extinguisher ready.	Presence of standby person outside the equiptment .	Risk is Controlled.
6	Electrical shock.	Improper cable / cable connection of handlamp.	Use only standard & inspected cable and tools.	Periodical checking & testing of electrical cables and accessories	Use only 24 volt flame proof hand lamp.	Risk is Controlled.
	Others	In case of any emergency/injury	Wind direction,  Escape route, Assembly point,    Fire extinguisher     Manual call point,      Loudophone   Safety shower,Work carried out below or above	All the safety measures provided in the plant nearest to the job must be spotted before job starts.	Supervisor shall explain all these during the tool box talk before start of each job.	Risk is controlled.
	NOTE: This risk assessment is valid if surrounding conditions are normal. It will change according to the change in surrounding conditions.

		ACTIVITY : Hot work jobs in vessels / columns and pipelines.
		FREQUENCY :	As & when required
		PURPOSE OF JOB :	Repairing of pipe lines, structure, ducting, replacement of piping components, supports.
		SUB ACTIVITIES :	1. Gas cutting.
			2. Grinding.
			3. Welding of any kind.
SUB ACTI. SR. NO.	HAZARDS THAT MAY BE ENCOUNTERED	SOURCE / CAUSE OF HAZARD	CONTROL MEASURES PROVIDED	CONTROL MEASURES TO BE PROVIDED	ADDITIONAL SAFETY PRECAUTION / INSTRUCTIONS	RISK ANALYSIS
1 to 3	Fire / explosion.	Leakage of hydrocarbon / Presence of hydrocarbon inside vessel	1. Ensure that the job is taken up under hot work permit. 2. Ensure that the area is hydrocarbon free before start of the job. 3. Check regularly with LEL detector.	1. Keep the area free of combustible material. 2. Keep fire extinguisher and adequate quantity of water or running water hose ready at the job site.	1. Confirm isolation, draining and purging. 2. Protect nearby pipeline flanges carrying hydrocarbons with wet asbestos blankets. 3. Contain spark with wet asbestos blankets. Keep electrode stubs in a container.	Risk is controlled.
		Leakage of hydrocarbon through nearby OWS	Ensure OWS nearby the work area to be covered with GI Sheet or wet blanket over the grating	1. Keep the area free of combustible material. 2. Keep fire extinguisher & running water hose ready at the job site.	NIL	Risk is controlled.
2,3	Electric shock.	Grinding machine / Welding machine.	1. Use certified Grinding machine and welding machine. 2.earthing is to be ensured while welding job.	Check and ensure the certification validity.	Ensure earthing continuity from grinding machine / welding machine to powersource.	Risk is controlled.
2,3	Electric shock	Connected power supply cables and welding cables.	1. All connections to the welding machine to be done with proper lugs. 2. Ensure routing of welding lead / return lead from welding machine to job and vice-versa.	No joints in the welding cables to be permitted.	1. Check welding holder for any crack or damage in the insulation. 2. Cables should not get wet.	Risk is controlled.
1	Flash back or Back fire	Gas cutting set	Use of flash back arrestors on gas cylinders	Gas cutting nozzle holes should be cleaned frequently for smooth flow of gases.	Check and confirm flash back arresters are installed before starting the job. Proper clamping of hose connections should be done.	Risk is controlled.
1	Cylinder catching fire / explosion.	D/A gas cylinder	Do not expose cylinders to direct sunlight. Provide protective caps for gas cylinder.	Protect the valve with caps during storage, use and transportation of gas cylinders.	1. Never roll cylinders on side / surface. 2. Use proper trolley for transportation. Keep cylinders vertically. 3. If required cover the cylinder mouth with wet blanket	Risk is controlled.
1	Bursting of hose, gas leak, fire.	Gas cutting set	Use standard color hoses (red or orange for DA and blue or green for Oxygen)	1. Proper clamping of hose connections should be done. 2. When gas cutting operation is off keep the hoses depressurised and properly stored.	1. Check and ensure hoses are in good condition. 2. Use standard spark lighter to light the torch. 3. First close the cylinder valve keeping gas torch valve open to empty the gas from hoses.	Risk is controlled.
1,3	Physical injury / irritation to eyes	Welding, gas cutting.	1. Use welding shield / helmet and leather gloves for welding & cutting goggles and leather gloves for gas cutting. 2. Use basic PPE's	1. Barricading of the welding spot to be done with asbestos blanket. 2. Also Grinding spark to be contained by barricading with asbestos blanket.	1. Keep electrode stubs in a container. 2. cordening of the hot work area.	Risk is controlled.
2	Physical injury.	Grinding.	Use basic PPE's .	Grinding wheels should not be used after date of expiry. Machine must have wheel guard.	identification of the job for grinding.	Risk is controlled.
1 to 3		Fall from height.	Certified Scaffolding to be used & full body harness with Double lanyard.	None	Check and ensure that double safety harness is properly tied.	Risk is controlled.
	Suffocation.	Confined space.	Oxygen to be checked before any entry in confined space.	1. Air hose to be provided where required. 2. Standby person to be provided out side the confined space. 3.Lifting arrangements including pulley & ropes to be kept ready for lifting the person in case of emergency.	None	Risk is controlled.
	Injury.	Lifting, shifting & placing heavy objects.	Use tested lifting tools with colour coding	None	selection of tools depending of the job undertaken.	Risk is controlled.
	Others	In case of any emergency/injury	Wind direction,  Escape route, Assembly point,    Fire extinguisher     Manual call point,      Loudophone   Safety shower,Work carried out below or above	All the safety measures provided in the plant nearest to the job must be spotted before job starts.	Supervisor shall explain all these during the tool box talk before start of each job.	Risk is controlled.
	NOTE: This risk assessment is valid if surrounding conditions are normal. It will change according to the change in surrounding conditions.

		ACTIVITY : EXTRUDER CUTTER HEAD REPLACEMENT
		FREQUENCY :	As per requirement.
		PURPOSE OF JOB :	To replace worn out / damaged cutter head.
		SUB ACTIVITIES :	1. Ensure electrical (Palletizer and main extruder motor) and process isolation.
			2. Removal of old cutter head from cutter shaft.
			3. Shifting of new cutter head from mechanical workshop.
			4. Inserting new cutter head on the cutter shaft and fixing the cutter head allen bolt.
			5. Shifting of old cutter head to mechanical workshop.
SUB ACTI. SR. NO.	HAZARDS THAT MAY BE ENCOUNTERED	SOURCE / CAUSE OF HAZARD	CONTROL MEASURES PROVIDED	CONTROL MEASURES TO BE PROVIDED	ADDITIONAL SAFETY PRECAUTION / INSTRUCTIONS	RISK ANALYSIS
1, 2, 4	Hot burn.	1. Hot die plate and PCW chamber. 2. Hot PCW water.	1. Complete draining of PCW chamber. 2. Electrical lock out on PCW pump and extruder motor.	1. Running water hose to be provided nearby. 2. Cross check electrical isolation by pushing local switch. 3. Use of basic PPE's.	1. Use of full sleeve leather gloves. 2. Tool box talk.	Risk is Controlled.
1 to 5	Physical injury.	Slippage due to dirty working place.	Ensure good house keeping before starting the job.	Use basic PPE's.	Tool box talk.	Risk is Controlled.
		Slip of tools during opening / boxing up of cutter head.	Hand gloves and other recommended PPE's.	Ensure proper cleaning of allen bolt socket before applying allen- key	Use of right size of allen key and extention lever for opening and tightening.	Risk is Controlled.
		Hand injury due to sharp edges of cutter blades.	1. Use of cut resistant leather hand gloves. 2. Ensure electrical lock out on cutter motor. 3. Ensure air supply for coarse movement of cutter shaft is blocked.	1. Hold cutter shaft at motor coupling during opening/ tightening of head bolt. 2. Ensure electrical lock out by pushing local switch. 3. Air supply valve to be closed and DO NOT OPERATE tag to be displayed on valve.	1. Tool box talk. 2. Use of special fixing plate while inserting / removing cutter head.	Risk is Controlled.
	Others	In case of any emergency/injury	Wind direction,  Escape route, Assembly point,    Fire extinguisher     Manual call point,      Loudophone   Safety shower,Work carried out below or above	All the safety measures provided in the plant nearest to the job must be spotted before job starts.	Supervisor shall explain all these during the tool box talk before start of each job.	Risk is controlled.

		ACTIVITY : HOSE CONNECTION FROM UTILITY POINT TO PROCESS EQUIPTMENT/ HOSE CONNECTION
		FREQUENCY :	Intermittent.
		PURPOSE OF JOB :	Temporary flow arrangement where piping does not exist and where purging, flushing, cleaning is required.
		SUB ACTIVITIES :	1. Deblinding.
			2. Connection of hose to the equiptment / vessel.
			3. Connection of hose to the utility point.
SUB ACTI. SR. NO.	HAZARDS THAT MAY BE ENCOUNTERED	SOURCE / CAUSE OF HAZARD	CONTROL MEASURES PROVIDED	CONTROL MEASURES TO BE PROVIDED	ADDITIONAL SAFETY PRECAUTION / INSTRUCTIONS	RISK ANALYSIS
1	Hydrocarbon / chem leak to atmosphere while deblinding.	Isolation valve passing. Hold up in line.	Use basic PPE's.	Contact area operator. Crack open the blind from opposite side. Open the valve slowly.	Tool box talk is to be given.	Risk is Controlled.
2	Splash from hose during operation.	Use of Non standard / Non tested / damaged hose.	Use basic PPE's.	Mark standard colour code on tested hose. Open isolation valve slowly and watch the leak if any for complete opening of the isolation valve. Use standard & tested hose only. Check physically the condition of entire length. Check for any groove on flange surface	Tool box talk is to be given.	Risk is Controlled.
		Bends and twisting of the hose.	Ensure straightness of the hose without any bend any twist.	Nil	Nil	Risk is Controlled.
	Physical injury.	Tools, wrong position of using it.	Use basic PPE's.	Periodic checking of tools. Use correct tools from right position	Tool box talk is to be given.	Risk is Controlled.
1,2,3		Fall of person due to Wet & slippery surface	Ensure working surface is free from oil ,water or any slippery material/algae formation	Ensure good house keeping.	Nil	Risk is Controlled.
	Others	In case of any emergency/injury	Wind direction,  Escape route, Assembly point,    Fire extinguisher     Manual call point,      Loudophone   Safety shower,Work carried out below or above	All the safety measures provided in the plant nearest to the job must be spotted before job starts.	Supervisor shall explain all these during the tool box talk before start of each job.	Risk is controlled.
	NOTE: This risk assessment is valid if surrounding conditions are normal. It will change according to the change in surrounding conditions.

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